Today, Packaging manufacturers, while facing constant pressure to produce top quality products, they’re also striving to reduce costs, to be competitive and being profitable.
This challenging business landscape calls for very efficient systems that can plan, schedule, execute and monitor the entire processes thereby providing real time, accurate view of the whole business.
canias ERP for Packaging Industry, by means of its flexibility and its embedded industry specific features, enables efficient management of all operations and processes specific to packaging industry such as the film production, printed/printless package production, rotogravure printing cylinder processes, etc…
The core processes managed by canias ERP for Packaging Industry;
Managing material specifications and its changes across all processes
Packaging industry consists of raw materials ranging from BOPP, CPP, MOPP, pearlized, metalized, PET, PP, PVC, PS, PA, EVOH, PE, and Thermoform films etc which are used for both printed and unprinted package production. Raw materials undergo various processes such as rotogravure (photogravure), flexo, offset, typography and serigraphy printing techniques for the production of printed packaging materials such as mono/multi-layered rollers, shrink/stretch/high-barrier films, wickets, bottomed papers, carrier bags, labels etc. Rotogravure printing cylinders undergo specific processes like steel cylinder production, nickel-chrome-copper plating and flexo stereotypes processes etc…
In these processes of producing packaging materials, it is required to follow various technical specifications of the materials like structure, printing type, printing dimension, color information, cylinder information etc. All these essential information should be tracked right from the sales process until the shipping is undertaken. There could be changes in design specifications or technical specifications, which are either initiated by the customer or by graphics design department and it is imperative to track these changes which are taking place. It is also essential to follow-up the inter-department work processes in order to identify these changes and to capture them from the point of its initiation. canias ERP ’s integrated Product Information Form (PIF) makes it possible to manage changes in specifications per material group across all the processes. It also keeps track of specification revisions across the integrated data flow encompassing multiple divisions.
Cylinder maintenance & follow-up
One of the main requirements in the production of printed packaging material is to manage and maintain the cylinders and printing blocks. Key requirements in maintaining cylinders including provision of rotogravure print, re-processing for dents ascertained during pre & post printing inspections, additional copper, chrome, nickel process and milling statuses etc. can controlled by canias ERP.
All such specifications regarding cylinders including pantone, color sequence, needle angle, photocell clearance etc. can be efficiently managed in the system. All history associated with a cylinder as to, when and for which material it has been produced, when a dent occurred, and when it has undergone additional copper process etc. can be followed by a unique registration number.
Criteria based calculation of component usage and production time
canias ERP makes it possible to ascertain the usage of the components in accordance to such criteria like density values per film, density and solid matter ratio values per liquid substances (such as solvent, ink, and glue), etc... It is also possible to ascertain the time incurred for the production of goods based on such values like machine speed, quantities produced etc…
Alternative material management
With the alternative material management feature, it is possible to maintain and use alternative material for each material component. System also facilitates possible material changes throughout the production process.
Managing of array infrastructure
canias ERP can determine the arrays based on all the operation processes undergone by the product while in the production process.
An array example for a product could be as follows:
Printing » 1st lamination » 2nd lamination » Slitting » Packaging
As a result of this feature, it is possible to conduct spaghetti analysis on all the production processes of the organization.
Lot number based traceability
By means of canias ERP, all finished products can be tracked based on the lot numbers of both raw materials and semi-finished materials as well as rollers used in the production. It is possible to know the number of printed, laminated, slit, or semi-finished materials, within the stock at any time throughout the production process. Besides, in case a product is returned by customer, it is possible to trace the processes history of respected product as well as lot information of the films, inks and glue used.
Barcode, weigh scale, dispensing systems and PLC integration
canias ERP manages the automation requirements of the packaging industry by enabling the preparation of labels at various stages without the need for any third party software. These requirements include the inner labels for raw materials, labeling for semi-finished materials, inner and outer roller labels for finished products and finally the customer specific pallet labels. Semi-finished materials and raw materials can be counted via manual terminals. Integration ability with precision weigh scales enables weighing of produced rollers which can be transmitted directly to canias ERP. Apart from this, process parameters maintained in the production machines can be transmitted to the system online. For instance, by enabling data flow from dispensing systems which are used for ink production, stock of inks can be controlled and actual cost of ink consumption can also be ascertained.
Efficiency rendered in slitting operations
Specific adaptations being introduced in canias ERP facilitates efficient & simplified planning in slitting of unprinted materials from jumbo rollers, or from mill rolls, in accordance to the various widths ordered by the customers. For the printed materials, slitting can be done to photocell width, and it is possible to calculate theoretical quantities in accordance with row and set logic. Baby rollers can be barcoded with lot numbers based on row of output from the machine in order to provide efficient traceability.
Consignment sales & procurement process automations
canias ERP has made it possible to control the production and re-processing of the cylinders. Thanks to this feature, packaging companies can keep track of all its cylinders’ with their registration number both in their on-site production and in their outsourced cylinder/printing block production process. Moreover, with EDI (Electronic Data Interchange) facility, integration can also be achieved with film suppliers and the receipt of these materials can be efficiently processed into stock. In case of consignment sales contracts executed with the customers, consumption of consignment goods and its invoicing can be efficiently integrated with customer’s system.